IllustrationON AUGUST 22 ABOUT 2:45 I WAS RETURNING HOME FROM TAKING MY DAUGHTER TO WORK ABOUT3-MILES AWAY AND I NOTICED SMOKE COMING FROM MY CAR I GET OUT TO LOOK UNDER THE HOOD AND I NOTICE FLAMES COMING FROM THE FRONT RIGHT END UNDER THE HOOD. I PANICKED GRABBED MY BELONGINGS AND CALLED 911 THE FIRE DEPT ARRIVED AND PUT THE FIRE OUT. *TR
2004 Volkswagen Passat
Owner reports · Recalls · Investigations
More warning signs than most Passat years
Owner complaints for the 2004 Volkswagen Passat are substantially higher than the model-year median of 110.
About this comparison →How this year compares
Owner complaints by model year
Compare all Passat years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
390–25K
3325–50K
4550–75K
4575–100K
37100–150K
18150K+
217 reports with mileage · 62 unknown
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
- Engine And Engine Cooling. Review the 59 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Power Train. Review the 38 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Seats. Review the 34 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
9 crash reports25 fire reports23 injury reports
Electrical System complaints
23 reportsOUR 2004 PASSAT'S BRAKE LIGHTS WENT OUT RECENTLY. THERE WAS NO WARNING LIGHT OR OTHER PROCESS THAT TOLD US THE LIGHTS WERE OUT. WE WERE ALMOST IN A CAR ACCIDENT BECAUSE THE DRIVER BEHIND US DIDN'T SEE OUR BRAKE LIGHTS. AFTER DOING RESEARCH I FOUND THAT VW ISSUED A RECALL FOR THE BRAKE LIGHT SWITCH IN 2007...BUT WE NEVER RECEI…
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OUR 2004 PASSAT'S BRAKE LIGHTS WENT OUT RECENTLY. THERE WAS NO WARNING LIGHT OR OTHER PROCESS THAT TOLD US THE LIGHTS WERE OUT. WE WERE ALMOST IN A CAR ACCIDENT BECAUSE THE DRIVER BEHIND US DIDN'T SEE OUR BRAKE LIGHTS. AFTER DOING RESEARCH I FOUND THAT VW ISSUED A RECALL FOR THE BRAKE LIGHT SWITCH IN 2007...BUT WE NEVER RECEIVED SUCH NOTICE. I THINK THIS IS A SERIOUS SAFETY ISSUE THAT SHOULD BE COMMUNICATED TO THE PUBLIC. *TR
I OWN A VOLKSWAGEN PASSAT 2004 MODEL. ON NOVEMBER THE 11TH 2008 AFTER WORKING THE NIGHT SHIFT AT MBUSI IN VANCE, ALABAMA, I GOT IN MY CAR TO GO HOME. I TURNED ON THE HEATED SEAT JUST AS I HAVE DONE FOR THE PAST 4 YEARS ONLY THIS TIME I GOT MORE HEAT THAN I WANTED. MY HEATED SEAT CAUGHT FIRE AND BURNED MY LEG. IN ATTEMPT TO E…
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I OWN A VOLKSWAGEN PASSAT 2004 MODEL. ON NOVEMBER THE 11TH 2008 AFTER WORKING THE NIGHT SHIFT AT MBUSI IN VANCE, ALABAMA, I GOT IN MY CAR TO GO HOME. I TURNED ON THE HEATED SEAT JUST AS I HAVE DONE FOR THE PAST 4 YEARS ONLY THIS TIME I GOT MORE HEAT THAN I WANTED. MY HEATED SEAT CAUGHT FIRE AND BURNED MY LEG. IN ATTEMPT TO EXTINGUISH THE FIRE, I WRENCHED MY BACK BY STOMPING OUT THE FIRE WITH MY FOOT. I DID NOT HAVE ANYTHING CLOSE TO ME TO USE WITH MY HANDS SO THEY WOULD NOT GET BURNED. I COULD NOT BELIEVE HOW FAST MY CAR FILLED WITH WORST SMELLING SMOKE I HAVE EVER SMELT. THE SEAT WAS ON FIRE BEFORE I EVEN LEFT THE PARKING LOT. IF I WOULD HAVE WAITED TWO MINUTES TO TURN ON MY SEAT, I WOULD HAVE BEEN ON INTERSTATE 20/59 DRIVING AT 70 MPH AND I CAN ONLY IMAGINE WHAT WOULD HAVE HAPPENED. THIS IS ONE OF THE WORST EXPERIENCES OF MY LIFE. VOLKSWAGEN HAS OFFERED TO REPLACE THE COVER ON THE CAR, REPLACE MY PANTS AND PAY MY MEDICAL BILLS, BUT WHAT ABOUT THE SEAT I WILL CONTINUE TO SIT ON, AND MY CONFIDENCE THAT THIS WILL NOT HAPPEN AGAIN. I AM HORRIFIED TO THINK ABOUT THE POTENTIAL FOR RECURRENCE AND I CANNOT OVERCOME MY ORDEAL I AM DEVASTATED AND HAVE LOST MY CONFIDENCE IN THE PROCESSES THAT ARE SUPPOSED TO PROTECT THE CONSUMER. *TR
INCIDENT DESCRIPTION = 2004 VW PASSAT HAD BEEN PREVIOUSLY REPORT SEVERAL FUEL CONSUMPTIONS PROBLEMS AT HOY FOX VW AND GAS ENDED UP LEAKING OUT OF FUEL TANK AND CAUSE A SPILL IN MY GARAGE AND DRIVE. HAZARD WAS INHALATION GAS IN A CLOSED IN AREA CAUSED HEAD ACHES/ NAUSEA/DIZZINESS/ FOR MY FAMILY AND I I HAVE HAD MUTIPLE PROBLEMS W…
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INCIDENT DESCRIPTION = 2004 VW PASSAT HAD BEEN PREVIOUSLY REPORT SEVERAL FUEL CONSUMPTIONS PROBLEMS AT HOY FOX VW AND GAS ENDED UP LEAKING OUT OF FUEL TANK AND CAUSE A SPILL IN MY GARAGE AND DRIVE. HAZARD WAS INHALATION GAS IN A CLOSED IN AREA CAUSED HEAD ACHES/ NAUSEA/DIZZINESS/ FOR MY FAMILY AND I I HAVE HAD MUTIPLE PROBLEMS WITH VEHICLE SINCE THEN HAS BROKE DOWN ON ME TWICE IN LESS THAN 1 DAY'S TIME. ON 01 SEP 08 MY WIFE NOTICED AND OIL SPOT IN DRIVEWAY AFTER I LEFT TO GO OUT OF TOWN GRANTED WE HAVE BRAND NEW HOME AND THE VW WAS ONLY VEHICLE PARKED IN THAT SPOT SHE COULD REACH ME BECAUSE NO SERVICE WITH MY CELL PHONE BUT I ENDED UP BROKE DOWN OUTSIDE BIG SPRING ,TX THE CARE WAS SLUGGISH AND LEAKING OIL THIS TIME AND ON 03 SEP08 IN /TEXARKANA AFTER BEING IN SHOP ALLDAY 2SEP08 IT BROKE DOWN FOR A PREVIOUS CONDITION WITH IGNITION COILS. HOY FOXVW NOT ADMITTING THAT MAY HAVE PUT THE NEW OIL FILTER TO TIGHT TO CAUSE TO BREAKDOWN AFTER HAVING THE OIL CHANGE ON 28AUG08/29AUG08 FOR OTHER NEGLECTED MAINTENANCE. PLEASE LOOK INTO THIS MATTER I'M SURE IT'S NOT JUST MY VEHICLE THEY TRYING TO ASSUME BECAUSE IT JUST HAD WENT OUT WARRANTY. THE ENGINE OIL COOLER WAS DAMAGED AND BURSTED WHEN PUT ON AT HOY-FOX VW BY A VW TECHNICIAN AFTER PUTTING THE OIL FILTER ON ENTIRELY TO TIGHT. LEAKED IN YARD AND I WAS NOT AWARE OF IT AND THE SPILLED OUT ALL OVER THE GROUND AT A HIGH TEMPERATURE VEHICLE (OVERHEATED) WHICH MAKE IT HARD FOR ME STOP WHILE DRIVE BECAUSE OF THE SLICKNESS OF MIXTURE BETWEEN THE COOLANT AND OIL. ALMOST RAN OFF THE ROAD BUT ENDED UP SHIFTING TO NEUTRAL AND LETTING COAST OVER TO MEDIAN. *TR
I HAVE HAD PROBLEMS WITH MY 2004 PASSAT INSTRUMENT PANEL SINCE THE FIRST YEAR I BOUGHT IT. THE PANEL WOULD SHOW FALSE "DOOR AJAR" WARNINGS AND "TRUNK AJAR" WARNINGS. ABOUT A YEAR LATER IT STARTED SHOWING THE "GAS LID AJAR" WARNING LIGHT. I REPORTED IT TO THE DEALERSHIP AND WAS TOLD THAT THERE WAS NO SUCH LIGHT. IT CONTINUED …
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I HAVE HAD PROBLEMS WITH MY 2004 PASSAT INSTRUMENT PANEL SINCE THE FIRST YEAR I BOUGHT IT. THE PANEL WOULD SHOW FALSE "DOOR AJAR" WARNINGS AND "TRUNK AJAR" WARNINGS. ABOUT A YEAR LATER IT STARTED SHOWING THE "GAS LID AJAR" WARNING LIGHT. I REPORTED IT TO THE DEALERSHIP AND WAS TOLD THAT THERE WAS NO SUCH LIGHT. IT CONTINUED TO HAPPEN, AND THE DEALERSHIP TOLD ME TO TAKE PICTURES OF THE WARNING NEXT TIME IT OCCURRED. THIS HAPPENED QUITE OFTEN, BUT THE WARRANTY RAN OUT BEFORE I COULD SHOW IT TO THEM AND THEY NOW SAY THAT IT'S NOT COVERED. THE INSTRUMENT WARNING PANEL NOW GETS SO DIM THAT YOU CAN'T READ IT WHEN THE CAR GETS TOO HOT SITTING IN THE SUN. ABOUT A YEAR AGO, THE ENGINE WARNING LIGHT CAME ON AND THE WARNING PANEL STATED, "STOP! TURN ENGINE OFF IMMEDIATELY." I WAS 320 MILES AWAY FROM HOME BY MYSELF AT THE TIME. I DISCOVERED THAT THERE WAS NO PROBLEM. IT WAS JUST A MALFUNCTIONING WARNING. TWO WEEKS AGO, THE ENGINE LIGHT CAME ON AGAIN, SO BECAUSE OF THE PAST FALSE SIGNALS, I IGNORED IT AND DROVE A 640 MILE ROUND TRIP BY MYSELF. A WEEK LATER, MY HUSBAND AND I WERE ON A TRIP AND THE ENGINE LIGHT WAS STILL ON. THE SECOND DAY OF THE TRIP, OUR CAR BATTERY WENT DEAD AND WE HAD TO REPLACE THE BATTERY. HAVING A FAULTY SYSTEM CAUSED ME TO DISREGARD THE WARNINGS AND, THEREFORE, HAD TO PURCHASE A NEW BATTERY. I AM THOROUGHLY DISGUSTED WITH VOLKSWAGENS PRODUCTS AND THE DEALERSHIPS SERVICE AND INTEGRITY. *TR
I HAVE A 2004 VW PASSAT 4MOTION 1.8 TURBO. I HAVE JUST RECENTLY (WITHIN THE LAST MONTH) REPLACED THE #2 COIL. NOW TODAY EITHER ANOTHER COIL IS GONE OR THE SAME ONE. I HAVEN'T GOTTEN IT TO MY MECHANIC YET TO DETERMINE WHICH ONE IS BAD. BUT AFTER TALKING TO HIM HE RELATED TO ME THAT HE HAS REPLACED SEVERAL # 2 COILS THIS YEAR…
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I HAVE A 2004 VW PASSAT 4MOTION 1.8 TURBO. I HAVE JUST RECENTLY (WITHIN THE LAST MONTH) REPLACED THE #2 COIL. NOW TODAY EITHER ANOTHER COIL IS GONE OR THE SAME ONE. I HAVEN'T GOTTEN IT TO MY MECHANIC YET TO DETERMINE WHICH ONE IS BAD. BUT AFTER TALKING TO HIM HE RELATED TO ME THAT HE HAS REPLACED SEVERAL # 2 COILS THIS YEAR ON THIS MAKE OF VEHICLE.. SO I AM JUST GUESSING THAT THIS IS THE PROBLEM THIS TIME AROUND. MY VEHICLE HAS 52,000 MILES ON IT. IT WASN'T THE #2 COIL IT WAS THE #1 COIL. I AM GETTING REALLY DISGUSTED WITH THIS CAR AS FAR AS RELIABILITY IS CONCERNED. I AM PLANNING ON A TRIP TO FLORIDA IN THE FALL AND AM WONDERING IF I SHOULD TAKE A CASE OF COILS WITH ME. I WAS AT THE DEALERS THE FIRST TIME THIS HAPPENED & ASKED ABOUT RECALLS ON THIS ITEM. THEY SAID THEY DIDN'T HAVE ANY.. I THOUGHT IT A BIT ODD BECAUSE MY MECHANIC TOLD ME HE HAS HAD SEVERAL COME THROUGH THIS YEAR WITH BAD COILS. *TR
1. NEW 2004 VOLKSWAGEN PASSAT, V6 SEDAN. RETURNED CAR SEVERAL TIMES UNDER WARRANTY FOR MANY TYPES OF REPAIRS. VOLKSWAGEN UNABLE TO REPAIR CAR. BOTH THE DEALER AND VOLKSWAGEN OF AMERICA WERE MADE AWARE OF THE PROBLEMS. 2. SEVERAL FAILURES INCLUDING BUT NOT LIMITED TO: EXCESSIVE OIL CONSUMPTION, LOSS OF POWER AND ACCELERAT…
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1. NEW 2004 VOLKSWAGEN PASSAT, V6 SEDAN. RETURNED CAR SEVERAL TIMES UNDER WARRANTY FOR MANY TYPES OF REPAIRS. VOLKSWAGEN UNABLE TO REPAIR CAR. BOTH THE DEALER AND VOLKSWAGEN OF AMERICA WERE MADE AWARE OF THE PROBLEMS. 2. SEVERAL FAILURES INCLUDING BUT NOT LIMITED TO: EXCESSIVE OIL CONSUMPTION, LOSS OF POWER AND ACCELERATION, TRANSMISSION PROBLEMS, FAILURE TO START, MALFUNCTION INDICATOR LAMP CONSTANTLY ON, BRAKING PROBLEMS, CLIMATE CONTROL PROBLEMS, AND SEVERAL ELECTRICAL PROBLEMS INCLUDING FAILED BRAKE LIGHTS. 3. SEVERAL ATTEMPTS BY VOLKSWAGEN HAS FAILED TO FIX THE PROBLEMS. THEY ARE UNWILLING TO RESOLVE THE PROBLEMS ADEQUATELY. *TR
2004 PASSAT 1.8T CAUGHT FIRE AFTER A COIL PACK FAILED AND THE CATALYTIC CONVERTER OVERHEATED. I ONLY DROVE 5 MILES AFTER THE COIL PACK FAILED TRYING TO LIMP BACK TO THE DEALER WHEN THE FIRE STARTED. I PUT THE FIRE OUT MYSELF. *TR
SUN VISOR W/HOMELINK CAUSES #5 FUSE TO BLOW. WIRES ARE SHORTING OUT INSIDE THE VISOR CAUSING SMOKE. WHEN FUSE BLOWS YOU LOOSE CLIMATRONIC AC, CRUISE CONTROL, AUTO DIMMING MIRRORS, AND STEERING WHEEL CONTROLS. *TR
THE 2004 VOLKSWAGEN PASSAT 1.8 T CAR ENGINE CAUGHT ON FIRE TODAY WHILE DRIVING THE DRIVER BARELY SAVED HIS LIFE FROM THE FLAMES. THE CAR WOULD CERTAINLY BURN COMPLETELY IF LUCKILY THERE WAS NO FIRE EXTINGUISHER AVAILABLE AT THE NEARBY STORES. ALTHOUGH THE INCIDENT WAS IN ISTANBUL, TURKEY I HAPPENED TO LEARN FROM THE INTERN…
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THE 2004 VOLKSWAGEN PASSAT 1.8 T CAR ENGINE CAUGHT ON FIRE TODAY WHILE DRIVING THE DRIVER BARELY SAVED HIS LIFE FROM THE FLAMES. THE CAR WOULD CERTAINLY BURN COMPLETELY IF LUCKILY THERE WAS NO FIRE EXTINGUISHER AVAILABLE AT THE NEARBY STORES. ALTHOUGH THE INCIDENT WAS IN ISTANBUL, TURKEY I HAPPENED TO LEARN FROM THE INTERNET THAT NHTSA WAS CONDUCTING AN INVESTIGATIONS ON THE SAME PROBLEM FOR 19 VOLKSWAGEN PASSATS. VOLKSWAGEN DEALER IN TURKEY TOLD ME THAT AN ENGINEER FROM VOLKSWAGEN GERMANY WILL COME TO TURKEY TO PERFORM AN INSPECTION ON THE CAR. NOBODY TOUCHED THE CAR YET. SINCE THE INCIDENT WAS TODAY ANT THE CAR WAS STILL AT THE VOLKSWAGEN AUTHORIZED DEALER SERVICE. I THOUGHT THIS INFORMATION MIGHT BE USEFULL FOR YOUR INVESTIGATION, AND WOULD LIKE TO LEARN YOUR SUGGESTIONS THAT YOU MAY WANT TO SHARE WITH ME. PLEASE WRITE TO MY E-MAIL ADRESS IN CASE YOU NEED DETAILED INFORMATION OR WOULD LIKE TO GET THE PHOTOES OF THE ENGINE CAUGHT ON FIRE. THANKS. *AK
Official recalls
308V156000 · Fuel System, Gasoline:delivery
Apr 7, 2008
VOLKSWAGEN IS RECALLING 412,000 MY 1999-2005 PASSAT (5TH GENERATION) VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSIONS AND PRODUCED AFTER JUNE 14, 1999. THESE VEHICLES MAY HAVE AN UNDERBODY HEAT SHIELD THAT CAN BECOME DAMAGED. IN ADDITION, AFFECTED VEHICLES WITH AUTOMATIC OR MANUAL TRANSMISSIONS MAY HAVE A FUEL LINE (1.8T ENGINES ONLY) OR FUEL TANK VENTILATION VALVE (4MOTION/ALL WHEEL DRIVE ONLY) THAT CAN LEAK DUE TO FRACTURE.
Consequence & remedy
Consequence: A HEAT SHIELD THAT MAY CONTACT THE EXHAUST SYSTEM CAN RESULT IN A VEHICLE FIRE. IN ADDITION, A FUEL LEAK FROM A FUEL LINE OR FUEL TANK VENTILATION VALVE, IN THE PRESENCE OF AN IGNITION SOURCE, CAN LEAD TO A VEHICLE FIRE.
Remedy: DEALERS WILL INSTALL ADDITIONAL UNDERBODY HEAT SHIELDS ON VEHICLES WITH AUTOMATIC TRANSMISSIONS TO COVER THE POSSIBLY DAMAGED AREAS AND FLASH ALL 1.8T ENGINES WITH A PRECAUTIONARY SOFTWARE UPDATE. DEALERS WILL ALSO INSPECT AND ADJUST THE FUEL LINE ROUTING ON 1.8T VEHICLES AND THE FUEL TANK VENTILATION VALVE ON 4MOTION/ALL WHEEL DRIVE VEHICLES, AND REPLACE COMPONENTS IF NECESSARY FREE OF CHARGE. THE RECALL BEGAN ON JUNE 13, 2008. OWNERS MAY CONTACT VOLKSWAGEN AT 1-800-822-8987.
07V063000 · Exterior Lighting:brake Lights:switch
Feb 20, 2007
ON CERTAIN PASSENGER, WAGON, AND CONVERTIBLE VEHICLES EQUIPPED WITH OR WITHOUT CRUISE CONTROL, A BRAKE LIGHT SWITCH MAY MALFUNCTION IF IT WAS INSTALLED INCORRECTLY.
Consequence & remedy
Consequence: THE BRAKE LIGHTS COULD BECOME INOPERATIVE, OR REMAIN ON. FAILURE TO PROVIDE THE PROPER SIGNAL WHEN BRAKING COULD LEAD TO A CRASH WITHOUT WARNING.
Remedy: DEALERS WILL INSTALL THE NEWLY DESIGNED BRAKE LIGHT SWITCH FREE OF CHARGE. THE RECALL BEGAN ON APRIL 27, 2007, AND WILL BE CONDUCTED IN SEVERAL STAGGERED MAILINGS THROUGH SEPTEMBER 21, 2007. VEHICLES WITHIN THE MAKE, MODEL, AND MODEL YEAR OF THIS POPULATION MAY BE INVOLVED IN EITHER THIS RECALL OR 06V-183, BUT NOT BOTH. THE REMEDY IS THE SAME FOR EACH RECALL. VOLKSWAGEN DEALERS WILL APPLY THE REMEDY BASED ON THE VIN NUMBER OF THE VEHICLE. OWNERS MAY CONTACT VW AT 1-800-822-8987.
04V586000 · Fuel System, Diesel
Dec 15, 2004
ON CERTAIN PASSENGER VEHICLES, THE HIGH PRESSURE DIESEL PUMPS WERE PRODUCED WITH AN IMPROPER FASTENER, WHICH COULD ALLOW DIESEL FUEL TO ESCAPE FROM THE PUMP.
Consequence & remedy
Consequence: FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE MAY LEAD TO A FIRE.
Remedy: DEALERS WILL REPLACE THE DIESEL PUMP. THE RECALL BEGAN ON FEBRUARY 8, 2005. OWNERS SHOULD CONTACT VOLKSWAGEN AT 1-800-822-8987.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
3EA11002 · Engine Compartment Fire
Opened Jan 26, 2011 · Closed Feb 17, 2012
Status: closed (inferred from source dates) · Electrical System; Engine And Engine Cooling
In July 2010, the Agency opened PE10-027 to investigate allegations of coil on plug (COP) ignition coil fires in MY2002-2003 VW Passat vehicles.The investigation was upgraded in January 2011 to include all MY2001-2007 4-cylinder VW Passat, gasoline, turbo-charged vehicles.Based on the analysis of VW's response, and including ODI's consumer complaints, ODI has since identified 135 unique engine fire reports attributable to the COP coils.After further review of the details as contained in each report, ODI determined that 43 of the 135 fire reports were actual fire/flame incidents, 83 fire reports were thermal events (smoke, spark, heat or wire melt), and another 9 fire reports were undetermined in severity due to the lack of information.These COP coil fires were characterized as initiated from within the COP coil circuit located at the top of the engine block and below the plastic engine cover.The fires observed were contained in the engine compartment and did not reach into the passenger compartment in contrast to those caused by an overheated catalytic converter examined in ODI?s investigation in 2007 and 2008.There were no reports of crashes or personal injury in this examination.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor this issue and reserves the right to take further action if warranted by the circumstancesSee the Closing Report for additional details.
Additional source detail variants (2)
Electrical System
In July 2010, the Agency opened PE10-027 to investigate allegations of coil on plug (COP) ignition coil fires in MY2002-2003 VW Passat vehicles.The investigation was upgraded in January 2011 to include all MY2001-2007 4-cylinder VW Passat, gasoline, turbo-charged vehicles.Based on the analysis of VW's response, and including ODI's consumer complaints, ODI has since identified 135 unique engine fire reports attributable to the COP coils.After further review of the details as contained in each report, ODI determined that 43 of the 135 fire reports were actual fire/flame incidents, 83 fire reports were thermal events (smoke, spark, heat or wire melt), and another 9 fire reports were undetermined in severity due to the lack of information.These COP coil fires were characterized as initiated from within the COP coil circuit located at the top of the engine block and below the plastic engine cover.The fires observed were contained in the engine compartment and did not reach into the passenger compartment in contrast to those caused by an overheated catalytic converter examined in ODI?s investigation in 2007 and 2008.There were no reports of crashes or personal injury in this examination.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor this issue and reserves the right to take further action if warranted by the circumstancesSee the Closing Report for additional details.
Engine And Engine Cooling
In July 2010, the Agency opened PE10-027 to investigate allegations of coil on plug (COP) ignition coil fires in MY2002-2003 VW Passat vehicles.The investigation was upgraded in January 2011 to include all MY2001-2007 4-cylinder VW Passat, gasoline, turbo-charged vehicles.Based on the analysis of VW's response, and including ODI's consumer complaints, ODI has since identified 135 unique engine fire reports attributable to the COP coils.After further review of the details as contained in each report, ODI determined that 43 of the 135 fire reports were actual fire/flame incidents, 83 fire reports were thermal events (smoke, spark, heat or wire melt), and another 9 fire reports were undetermined in severity due to the lack of information.These COP coil fires were characterized as initiated from within the COP coil circuit located at the top of the engine block and below the plastic engine cover.The fires observed were contained in the engine compartment and did not reach into the passenger compartment in contrast to those caused by an overheated catalytic converter examined in ODI?s investigation in 2007 and 2008.There were no reports of crashes or personal injury in this examination.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor this issue and reserves the right to take further action if warranted by the circumstancesSee the Closing Report for additional details.
PE08008 · Fuel Tank Leak
Opened Jan 31, 2008 · Closed May 30, 2008
Status: closed (inferred from source dates) · Fuel System, Gasoline:storage:tank Assembly; Fuel System, Other:storage:tank Assembly:pressure Relief Devices
VOLKSWAGEN (VW) IS RECALLING CERTAIN VW PASSAT 4MOTION AND AUDI A6 QUATTRO AND ALLROAD QUATTRO ALL-WHEEL DRIVE PASSENGER CARS.VW VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM NOVEMBER 22, 2000 THROUGH MAY 31, 2005 AND AUDI VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM JUNE 2, 2001 TO JUNE 1, 2005.THE NHTSA RECALL NUMBER FOR THE VW VEHICLES IS 08V-156 (VW ALSO IS CORRECTING DEFECTS RELATED TO HEAT SHIELD AND FUEL LINE HAZARDS FOR THESE VEHICLES AND FOR 1999-2000 PASSATS IN THIS RECALL ACTION.)THE NHTSA RECALL NUMBER FOR THE AUDI VEHICLES IS 08V-157.SINCE 2006, ODI HAS RECEIVED 17 COMPLAINTS OF FUEL LEAKING FROM THE SUBJECT VEHICLES' FUEL TANKS.THE 400 COMPLAINTS SHOWN ABOVE MAY INCLUDE DUPLICATE REPORTS TO ODI AND THE MANUFACTURER. WHILE THE CONSEQUENCE (FUEL LEAKS FROM THE TOP OF THE TANK) IS SIMILAR FOR BOTH THE PASSAT AND AUDI SUBJECT VEHICLES, DIFFERENCES IN DESIGN AND CONSTRUCTION REQUIRE A DIFFERENT REMEDY FOR EACH VEHICLE.ON THE PASSATS, THE VENTILATION LINE COULD HAVE BEEN INSTALLED IMPROPERLY WITH TENSION AND WITH AN INCORRECTLY POSITIONED CABLE TIE.THE TENSION COULD CAUSE CRACKED OR BROKEN NIPPLES ON THE FUEL TANK ROLLOVER VALVE.ON THE AUDI VEHICLES, A MATERIAL CHANGE (EFFECTIVE JUNE 2, 2001) WITH DIFFERENT AGING CHARACTERISTICS USED FOR THE ROLLOVER VALVE AND THE USE OF AN INFLEXIBLE ALUMINUM VENTILATION LINE COULD CAUSE CRACKING OF THE NIPPLE ON THE ROLLOVER VALVE.VW IS RECALLING ALL VEHICLES SUBJECT TO THESE DEFECTS.IT WILL INSPECT PASSATS TO ENSURE THAT THE VENT LINE IS TENSION FREE AND CORRECT THE INSTALLATION IF TENSION IS FOUND.IF A CRACK OR FUEL LEAK IS FOUND, VW WILL REPLACE THE FUEL TANK.AUDI WILL REPAIR ALL SUBJECT VEHICLES BY REINFORCING THE FUEL TANK ROLLOVER VALVE WITH AN EPOXY ADHESIVE.THIS INVESTIGATION IS CLOSED.
Additional source detail variants (4)
Fuel System, Gasoline:storage:tank Assembly
VOLKSWAGEN (VW) IS RECALLING CERTAIN VW PASSAT 4MOTION AND AUDI A6 QUATTRO AND ALLROAD QUATTRO ALL-WHEEL DRIVE PASSENGER CARS.VW VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM NOVEMBER 22, 2000 THROUGH MAY 31, 2005 AND AUDI VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM JUNE 2, 2001 TO JUNE 1, 2005.THE NHTSA RECALL NUMBER FOR THE VW VEHICLES IS 08V-156 (VW ALSO IS CORRECTING DEFECTS RELATED TO HEAT SHIELD AND FUEL LINE HAZARDS FOR THESE VEHICLES AND FOR 1999-2000 PASSATS IN THIS RECALL ACTION.)THE NHTSA RECALL NUMBER FOR THE AUDI VEHICLES IS 08V-157.SINCE 2006, ODI HAS RECEIVED 17 COMPLAINTS OF FUEL LEAKING FROM THE SUBJECT VEHICLES' FUEL TANKS.THE 400 COMPLAINTS SHOWN ABOVE MAY INCLUDE DUPLICATE REPORTS TO ODI AND THE MANUFACTURER. WHILE THE CONSEQUENCE (FUEL LEAKS FROM THE TOP OF THE TANK) IS SIMILAR FOR BOTH THE PASSAT AND AUDI SUBJECT VEHICLES, DIFFERENCES IN DESIGN AND CONSTRUCTION REQUIRE A DIFFERENT REMEDY FOR EACH VEHICLE.ON THE PASSATS, THE VENTILATION LINE COULD HAVE BEEN INSTALLED IMPROPERLY WITH TENSION AND WITH AN INCORRECTLY POSITIONED CABLE TIE.THE TENSION COULD CAUSE CRACKED OR BROKEN NIPPLES ON THE FUEL TANK ROLLOVER VALVE.ON THE AUDI VEHICLES, A MATERIAL CHANGE (EFFECTIVE JUNE 2, 2001) WITH DIFFERENT AGING CHARACTERISTICS USED FOR THE ROLLOVER VALVE AND THE USE OF AN INFLEXIBLE ALUMINUM VENTILATION LINE COULD CAUSE CRACKING OF THE NIPPLE ON THE ROLLOVER VALVE.VW IS RECALLING ALL VEHICLES SUBJECT TO THESE DEFECTS.IT WILL INSPECT PASSATS TO ENSURE THAT THE VENT LINE IS TENSION FREE AND CORRECT THE INSTALLATION IF TENSION IS FOUND.IF A CRACK OR FUEL LEAK IS FOUND, VW WILL REPLACE THE FUEL TANK.AUDI WILL REPAIR ALL SUBJECT VEHICLES BY REINFORCING THE FUEL TANK ROLLOVER VALVE WITH AN EPOXY ADHESIVE.THIS INVESTIGATION IS CLOSED.
Fuel System, Gasoline:storage:tank Assembly
VOLKSWAGEN (VW) IS RECALLING CERTAIN VW PASSAT 4MOTION AND AUDI A6 QUATTRO AND ALLROAD QUATTRO ALL-WHEEL DRIVE PASSENGER CARS.VW VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM NOVEMBER 22, 2000 THROUGH MAY 31, 2005 AND AUDI VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM JUNE 2, 2001 TO JUNE 1, 2005.THE NHTSA RECALL NUMBER FOR THE VW VEHICLES IS 08V-156 (VW ALSO IS CORRECTING DEFECTS RELATED TO HEAT SHIELD AND FUEL LINE HAZARDS FOR THESE VEHICLES AND FOR 1999-2000 PASSATS IN THIS RECALL ACTION.)THE NHTSA RECALL NUMBER FOR THE AUDI VEHICLES IS 08V-157.SINCE 2006, ODI HAS RECEIVED 17 COMPLAINTS OF FUEL LEAKING FROM THE SUBJECT VEHICLES' FUEL TANKS.THE 400 COMPLAINTS SHOWN ABOVE MAY INCLUDE DUPLICATE REPORTS TO ODI AND THE MANUFACTURER. WHILE THE CONSEQUENCE (FUEL LEAKS FROM THE TOP OF THE TANK) IS SIMILAR FOR BOTH THE PASSAT AND AUDI SUBJECT VEHICLES, DIFFERENCES IN DESIGN AND CONSTRUCTION REQUIRE A DIFFERENT REMEDY FOR EACH VEHICLE.ON THE PASSATS, THE VENTILATION LINE COULD HAVE BEEN INSTALLED IMPROPERLY WITH TENSION AND WITH AN INCORRECTLY POSITIONED CABLE TIE.THE TENSION COULD CAUSE CRACKED OR BROKEN NIPPLES ON THE FUEL TANK ROLLOVER VALVE.ON THE AUDI VEHICLES, A MATERIAL CHANGE (EFFECTIVE JUNE 2, 2001) WITH DIFFERENT AGING CHARACTERISTICS USED FOR THE ROLLOVER VALVE AND THE USE OF AN INFLEXIBLE ALUMINUM VENTILATION LINE COULD CAUSE CRACKING OF THE NIPPLE ON THE ROLLOVER VALVE.VW IS RECALLING ALL VEHICLES SUBJECT TO THESE DEFECTS.IT WILL INSPECT PASSATS TO ENSURE THAT THE VENT LINE IS TENSION FREE AND CORRECT THE INSTALLATION IF TENSION IS FOUND.IF A CRACK OR FUEL LEAK IS FOUND, VW WILL REPLACE THE FUEL TANK.AUDI WILL REPAIR ALL SUBJECT VEHICLES BY REINFORCING THE FUEL TANK ROLLOVER VALVE WITH AN EPOXY ADHESIVE.THIS INVESTIGATION IS CLOSED.
Fuel System, Other:storage:tank Assembly:pressure Relief Devices
VOLKSWAGEN (VW) IS RECALLING CERTAIN VW PASSAT 4MOTION AND AUDI A6 QUATTRO AND ALLROAD QUATTRO ALL-WHEEL DRIVE PASSENGER CARS.VW VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM NOVEMBER 22, 2000 THROUGH MAY 31, 2005 AND AUDI VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM JUNE 2, 2001 TO JUNE 1, 2005.THE NHTSA RECALL NUMBER FOR THE VW VEHICLES IS 08V-156 (VW ALSO IS CORRECTING DEFECTS RELATED TO HEAT SHIELD AND FUEL LINE HAZARDS FOR THESE VEHICLES AND FOR 1999-2000 PASSATS IN THIS RECALL ACTION.)THE NHTSA RECALL NUMBER FOR THE AUDI VEHICLES IS 08V-157.SINCE 2006, ODI HAS RECEIVED 17 COMPLAINTS OF FUEL LEAKING FROM THE SUBJECT VEHICLES' FUEL TANKS.THE 400 COMPLAINTS SHOWN ABOVE MAY INCLUDE DUPLICATE REPORTS TO ODI AND THE MANUFACTURER. WHILE THE CONSEQUENCE (FUEL LEAKS FROM THE TOP OF THE TANK) IS SIMILAR FOR BOTH THE PASSAT AND AUDI SUBJECT VEHICLES, DIFFERENCES IN DESIGN AND CONSTRUCTION REQUIRE A DIFFERENT REMEDY FOR EACH VEHICLE.ON THE PASSATS, THE VENTILATION LINE COULD HAVE BEEN INSTALLED IMPROPERLY WITH TENSION AND WITH AN INCORRECTLY POSITIONED CABLE TIE.THE TENSION COULD CAUSE CRACKED OR BROKEN NIPPLES ON THE FUEL TANK ROLLOVER VALVE.ON THE AUDI VEHICLES, A MATERIAL CHANGE (EFFECTIVE JUNE 2, 2001) WITH DIFFERENT AGING CHARACTERISTICS USED FOR THE ROLLOVER VALVE AND THE USE OF AN INFLEXIBLE ALUMINUM VENTILATION LINE COULD CAUSE CRACKING OF THE NIPPLE ON THE ROLLOVER VALVE.VW IS RECALLING ALL VEHICLES SUBJECT TO THESE DEFECTS.IT WILL INSPECT PASSATS TO ENSURE THAT THE VENT LINE IS TENSION FREE AND CORRECT THE INSTALLATION IF TENSION IS FOUND.IF A CRACK OR FUEL LEAK IS FOUND, VW WILL REPLACE THE FUEL TANK.AUDI WILL REPAIR ALL SUBJECT VEHICLES BY REINFORCING THE FUEL TANK ROLLOVER VALVE WITH AN EPOXY ADHESIVE.THIS INVESTIGATION IS CLOSED.
Fuel System, Other:storage:tank Assembly:pressure Relief Devices
VOLKSWAGEN (VW) IS RECALLING CERTAIN VW PASSAT 4MOTION AND AUDI A6 QUATTRO AND ALLROAD QUATTRO ALL-WHEEL DRIVE PASSENGER CARS.VW VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM NOVEMBER 22, 2000 THROUGH MAY 31, 2005 AND AUDI VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM JUNE 2, 2001 TO JUNE 1, 2005.THE NHTSA RECALL NUMBER FOR THE VW VEHICLES IS 08V-156 (VW ALSO IS CORRECTING DEFECTS RELATED TO HEAT SHIELD AND FUEL LINE HAZARDS FOR THESE VEHICLES AND FOR 1999-2000 PASSATS IN THIS RECALL ACTION.)THE NHTSA RECALL NUMBER FOR THE AUDI VEHICLES IS 08V-157.SINCE 2006, ODI HAS RECEIVED 17 COMPLAINTS OF FUEL LEAKING FROM THE SUBJECT VEHICLES' FUEL TANKS.THE 400 COMPLAINTS SHOWN ABOVE MAY INCLUDE DUPLICATE REPORTS TO ODI AND THE MANUFACTURER. WHILE THE CONSEQUENCE (FUEL LEAKS FROM THE TOP OF THE TANK) IS SIMILAR FOR BOTH THE PASSAT AND AUDI SUBJECT VEHICLES, DIFFERENCES IN DESIGN AND CONSTRUCTION REQUIRE A DIFFERENT REMEDY FOR EACH VEHICLE.ON THE PASSATS, THE VENTILATION LINE COULD HAVE BEEN INSTALLED IMPROPERLY WITH TENSION AND WITH AN INCORRECTLY POSITIONED CABLE TIE.THE TENSION COULD CAUSE CRACKED OR BROKEN NIPPLES ON THE FUEL TANK ROLLOVER VALVE.ON THE AUDI VEHICLES, A MATERIAL CHANGE (EFFECTIVE JUNE 2, 2001) WITH DIFFERENT AGING CHARACTERISTICS USED FOR THE ROLLOVER VALVE AND THE USE OF AN INFLEXIBLE ALUMINUM VENTILATION LINE COULD CAUSE CRACKING OF THE NIPPLE ON THE ROLLOVER VALVE.VW IS RECALLING ALL VEHICLES SUBJECT TO THESE DEFECTS.IT WILL INSPECT PASSATS TO ENSURE THAT THE VENT LINE IS TENSION FREE AND CORRECT THE INSTALLATION IF TENSION IS FOUND.IF A CRACK OR FUEL LEAK IS FOUND, VW WILL REPLACE THE FUEL TANK.AUDI WILL REPAIR ALL SUBJECT VEHICLES BY REINFORCING THE FUEL TANK ROLLOVER VALVE WITH AN EPOXY ADHESIVE.THIS INVESTIGATION IS CLOSED.
EA07014 · Passenger Engine Compartment Fires
Opened Sep 28, 2007 · Closed Jul 7, 2008
Status: closed (inferred from source dates) · Electrical System:ignition; Engine And Engine Cooling:exhaust System
THE MANUFACTURER NOTIFIED NHTSA ON 04-APR-08 THAT A SAFETY RECALL ACTION WOULD BE INITIATED TO REMEDY THE ISSUE.IN JUNE 2008, THE MANUFACTURER ISSUED A TECHNICAL SERVICE BULLETIN (CODE 26E5/R5) REGARDING THE SPECIFIC PROCEDURES TO BE EMPLOYED IN THIS CAMPAIGN.VEHICLE OWNER NOTIFICATION LETTERS WERE SENT BEGINNING APPROXIMATELY JUNE 13, 2008.THE CAMPAIGN WAS ASSIGNED NHTSA NO. 08V-156.THIS RECALL AFFECTS ALL MY 1999-2005, 5TH GENERATION GASOLINE-POWERED PASSAT SEDANS AND STATION WAGONS.APPROXIMATELY 412,000 VEHICLES ARE AFFECTED.CORRECTIVE ACTION WILL CONSIST OF INSTALLING ADDITIONAL EXHAUST SYSTEM HEAT SHIELDING TO MITIGATE THE POTENTIAL THERMAL EFFECTS OF ENGINE IGNITION PROBLEMS.BASED ON THIS ACTION, THE SUBJECT EA HAS BEEN CLOSED.
Additional source detail variants (2)
Electrical System:ignition
THE MANUFACTURER NOTIFIED NHTSA ON 04-APR-08 THAT A SAFETY RECALL ACTION WOULD BE INITIATED TO REMEDY THE ISSUE.IN JUNE 2008, THE MANUFACTURER ISSUED A TECHNICAL SERVICE BULLETIN (CODE 26E5/R5) REGARDING THE SPECIFIC PROCEDURES TO BE EMPLOYED IN THIS CAMPAIGN.VEHICLE OWNER NOTIFICATION LETTERS WERE SENT BEGINNING APPROXIMATELY JUNE 13, 2008.THE CAMPAIGN WAS ASSIGNED NHTSA NO. 08V-156.THIS RECALL AFFECTS ALL MY 1999-2005, 5TH GENERATION GASOLINE-POWERED PASSAT SEDANS AND STATION WAGONS.APPROXIMATELY 412,000 VEHICLES ARE AFFECTED.CORRECTIVE ACTION WILL CONSIST OF INSTALLING ADDITIONAL EXHAUST SYSTEM HEAT SHIELDING TO MITIGATE THE POTENTIAL THERMAL EFFECTS OF ENGINE IGNITION PROBLEMS.BASED ON THIS ACTION, THE SUBJECT EA HAS BEEN CLOSED.
Engine And Engine Cooling:exhaust System
THE MANUFACTURER NOTIFIED NHTSA ON 04-APR-08 THAT A SAFETY RECALL ACTION WOULD BE INITIATED TO REMEDY THE ISSUE.IN JUNE 2008, THE MANUFACTURER ISSUED A TECHNICAL SERVICE BULLETIN (CODE 26E5/R5) REGARDING THE SPECIFIC PROCEDURES TO BE EMPLOYED IN THIS CAMPAIGN.VEHICLE OWNER NOTIFICATION LETTERS WERE SENT BEGINNING APPROXIMATELY JUNE 13, 2008.THE CAMPAIGN WAS ASSIGNED NHTSA NO. 08V-156.THIS RECALL AFFECTS ALL MY 1999-2005, 5TH GENERATION GASOLINE-POWERED PASSAT SEDANS AND STATION WAGONS.APPROXIMATELY 412,000 VEHICLES ARE AFFECTED.CORRECTIVE ACTION WILL CONSIST OF INSTALLING ADDITIONAL EXHAUST SYSTEM HEAT SHIELDING TO MITIGATE THE POTENTIAL THERMAL EFFECTS OF ENGINE IGNITION PROBLEMS.BASED ON THIS ACTION, THE SUBJECT EA HAS BEEN CLOSED.